26-23

Secondary Air Injection

system
Function

The Secondary Air Injection system blows in air

behind the exhaust valves during cold start (+5
C to +33 C Engine Coolant Temperature) for
100 seconds, maximum. This produces an
oxygen-rich exhaust gas, causing afterburning
and reducing the duration of the catalyst heat-up
phase. Activation is initiated by the Motronic
Engine Control Module -J220- via the Secondary
Air Injection pump relay -J229- to the Secondary
Air Injection solenoid valve -N112-1) and combi-
valve.

Also, after each subsequent engine start (up to a

96 C max. Engine Coolant Temperature), the
Secondary Air Injection system will switch on for
10 seconds during idle and is then monitored by
the system. During this procedure the oxygen
sensor must be active.

1) Only engine code AEG

 26-24

Secondary Air Injection system components,

removing and installing

Note:
Components marked with an * are checked via the On
Board Diagnostic (OBD) system

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection &

Ignition, Engine Code(s): AEG, Repair Group 01

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection &

Ignition, Engine Code(s): AVH, Repair Group 01

Components marked with ** are checked via Output

Diagnostic Test mode

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection &

Ignition, Engine Code(s): AEG, Repair Group 01

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection &

Ignition, Engine Code(s): AVH, Repair Group 01
 26-25

1 - 2-pin harness connector

Black
2 - Secondary Air Injection valve -N112-*/**

Only engine code AEG

Fastened to cowl panel
3 - To connection on pipe to brake booster
Only engine code AEG
Ensure it is tightly seated
4 - Secondary Air Injection pump motor relay -J299-
*/**
Engine compartment left, on fuse/relay panel next to
brake master cylinder
Relay designation "100"
5 - O-ring
Replace if damaged
 26-26

6 - Pressure hose
Ensure it is tightly seated
Press together at ends to release
7 - Intake hose
From air filter upper section
Ensure it is tightly seated
Press together at ends to release
8 - Secondary Air Injection pump motor -V101-**
Engine code AVH, AZG not checked via Output
Diagnostic Test mode
Checking Page 26-30
9 - 10 Nm (7 ft lb)
10 - Bracket
For Secondary Air Injection pump motor -V101-
Attached to intake manifold lower section
11 - 2-pin harness connector
Black
 26-27

12 - 25 Nm (18 ft lb)
13 - Intake manifold - lower section
14 - To union on exhaust manifold
15 - 30 Nm (22 ft lb)
16 - Connecting pipe
17 - 35 Nm (26 ft lb)
18 - Warm air collector plate
19 - Gasket
Always replace
20 - Combi-valve
No connection on secondary air injection valve for
engine code AVH, AZG
Checking Page 26-28
Removing and installing: Page 26-39
 26-28

Combi-valve, checking

(Engine code AEG)

Special tools

V.A.G 1390 Hand vacuum pump

Test requirements

No Diagnostic Trouble Codes (DTCs) stored in DTC memory:

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s):
AEG, Repair Group 01

Output diagnostic test mode, activating:

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s):
AEG, Repair Group 01

Vacuum lines and seals not leaking

Vacuum lines not clogged or crimped
 26-29

Test procedure

- Remove upper engine cover.

- Disconnect vacuum hose -1- from Secondary Air Injection solenoid valve -N112-
-2-.
- Connect V.A.G 1390 hand vacuum pump to vacuum hose -1-.

Note:

Do not use compressed air during the following check!

- Remove pressure hose (arrow) between Secondary Air Injection pump motor
and connecting pipe.

Note:

Press together at ends to release.

- Blow into pressure hose with slight pressure (arrow).

Combi-valve must remain closed.
- Operate hand vacuum pump.
Combi-valve must open.

If combi-valve does not open:

- Replace combi-valve Page 26-39 .
 26-30

Secondary Air Injection pump motor -V101-,

checking

Special tools

V.A.G 1527B Voltage tester

VW 1594 Adaptor set
V.A.G 1598/22 Test Box for engine code AEG
V.A.G 1598/31 Test Box for engine codes AVH, AZG (not
shown)
 26-31

Test conditions

Main fuses must be OK.

Battery voltage 11.5 V minimum.

Test procedure

- Remove upper engine cover.

- Remove pressure hose on Secondary Air Injection pump motor (arrow).

Note:

Press together at end to release.

- Remove windshield wiper arms and cowl panel:

Repair Manual, Electrical Equipment, Repair Group 92

 26-32

- For engine code AEG connect V.A.G 1598/22 Test Box to ECM wiring harness.

- For engine code AVH, AZG connect V.A.G 1598/31 Test Box to ECM wiring
harness.
- Switch ignition ON.
- Bridge Test Box sockets with jumper wires from VW 1594 adaptor kit.
Engine code AEG: Socket 01 + 30
Engine codes AVH, AZG: Socket 01 + 9
Secondary Air Injection pump motor -V101- must run and air must exit from the
connecting hose.

If motor runs, but no air exits hose:

 26-33

- Switch ignition OFF.

- Replace Secondary Air Injection pump motor -

V101- Page 26-26 (item 8 ).

If the Secondary Air pump motor -V101- does not

run:

- Pull 2-pin connector off Secondary Air pump motor -V101- (arrow).

- Connect V.A.G 1527 B Voltage Tester to terminals of wiring connector using

jumper wires from VW 1594 Adaptor kit.
LED must light-up

If LED lights up (voltage supply OK):

- Replace Secondary Air Injection pump motor -V101- Page 26-26 (item 8 ).
 26-34

LED does not light up:

- Reconnect 2-pin harness connector.

- Perform output diagnostic test and check

activation of Secondary Air Injection pump motor
relay -J299-:

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel

Injection & Ignition, Engine Code(s): AEG, Repair
Group 01

- Check Diagnostic Trouble Code (DTC)

memory:

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel

Injection & Ignition, Engine Code(s): AEG, Repair
Group 01

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel

Injection & Ignition, Engine Code(s): AVH, Repair
Group 01
- Display Readiness code:

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel

Injection & Ignition, Engine Code(s): AEG, Repair
Group 01

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel

Injection & Ignition, Engine Code(s): AVH, Repair
Group 01

- Readiness code must be reset if ECM is subject

to low voltage with ignition ON or if DTC memory
is erased.

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel

Injection & Ignition, Engine Code(s): AEG, Repair
Group 01

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel

Injection & Ignition, Engine Code(s): AVH, Repair
Group 01
 26-35

Secondary Air Injection solenoid valve -

N112-, checking

(Engine code AEG)

Special tools

V.A.G 1594 A or VW 1594 Adaptor kit

V.A.G 1527 B Voltage Tester

Checking requirements

Engine oil temperature 5 to 33 C

Secondary Air Injection pump motor -V101- OK Page 26-30
 26-36

Test sequence

- Pull vacuum hose (arrow) off Secondary Air Injection solenoid valve -N112- -1-.
- Start engine and let run at idle.
When Secondary Air Injection pump motor -V101- runs, intake manifold
vacuum must be perceptible at disconnected vacuum port.

If no vacuum perceptible:

- Switch engine OFF.

- Disconnect 2-pin harness connector from Secondary Air Injection solenoid valve
-N112- (arrow).
 26-37

- Connect V.A.G 1527 B Voltage Tester to disconnected connector using jumper

wires from VW 1594 Adaptor kit.
- Start engine and let idle.
LED must light up.

LED lights up (voltage supply OK):

- Replace Secondary Air Injection solenoid valve -N112- Page 26-25 (item 2 ).

If LED does not light up:

- Connect 2-pin harness connector.

- Perform output diagnostic test and check activation of Secondary Air Injection
solenoid valve N112

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s):
AEG, Repair Group 01

- Check Diagnostic Trouble Code (DTC) memory:

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s):
AEG, Repair Group 01

- Display Readiness code:

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s):
AEG, Repair Group 01
 26-38

- Readiness code must be reset if ECM is subject

to low voltage with ignition ON or if DTC memory
is erased.

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel

Injection & Ignition, Engine Code(s): AEG, Repair
Group 01
 26-39

Combi-valve, removing and installing

Special tools

V.A.G 1331 Torque wrench 5 to 50 Nm (3.7 to 37 ft lb), or equivalent

VAS 5085 conductor

Note:
Always replace all seals and gaskets
A second technician is required for installation.

Removing

- Remove engine cover.

- Remove intake hose between Air Cleaner and Secondary Air Injection pump
motor -V101-.

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s):
AEG, Repair Group 24

Repair Manual, 2.0 Liter 4-Cyl. 2V Fuel Injection & Ignition, Engine Code(s):
AVH, Repair Group 24

- Remove pressure hose between Secondary Air Injection pump motor -V101- and
combi-valve from combi-valve.
 26-40

Note:

Press together at end to release.

- For engine code AEG remove vacuum hose

from combi-valve.

- Loosen sealing nuts on connecting pipe.

- Remove protective cover for right drive shaft.

- Unscrew connector pipe from exhaust

manifold.

- Unscrew combi-valve using ratchet handle and 4

mm allen socket.

Installing

- Thread front bolts through warm air collector

plate from below using tool.

- Second technician stops fasteners turning from

above.
- Install 4 mm inner hex with ratchet handle in
screw head.

- Have second technician position combi-valve

from above and also guide it during fastening of
second bolt.

Tightening torque: 10 Nm (7 ft lb)

Note:

Assembly is the reverse of the disassembly

procedure.

Tightening torques Page 26-24